Hi again Boa. I tried your suggestions but couldn’t get them to work for me 
I tried the fbx converter first. Just for an experiment I exported my low res as an obj from zbrush. I converted it to fbx, and then directly back to obj using the converter. When I tried to import back into zbrush it said the models don’t match… face count or vertice count blah blah. I can’t remember the exact error message at the moment. I tried with, and without the mrg option in zbrush too.
Why can’t stuff just work?!@!
Just for fun I tried TVeyes morph target method for switching uvs. I export my low res as obj, import to max, slap an unwrap uvw and automatic flaten mapping, collapse the stack (not sure if that’s necessary) then I export. I create a morph target in zbrush, then I import the obj with new uvs. I then hit switch to hopefully fix whatever is screwing up. I go up to the next subdivision level to make sure everything is ok and my model blows up again. Surprise! 
I’m not sure I understand what you mean about the cage method you describe. Would I just export my model at its lowest subdivision level as usual, tweak it in max, then hit the cage button before importing back? Or do I hit the cage button before exporting, and before importing back?
When I hit the cage button I get a really ugly low res cage compared to the interpolated one zbrush has created based on the high res. I’d like to work on the interpolated low res model if possible.
The displacement method sounds interesting. I can’t say I thought of trying that. I’m going to look up that thread and try that out as well.
I’ve actually adjusted my workflow to avoid the need to export my low res model after subdividing and detailing it so hopefully I won’t have to deal with this at all, but since I have encountered it it’s still bugging me! It would be nice to know that if I need to tweak my low res outside zbrush after subdividing it and detailing etc I could. Oh well I guess for now.
Your help is appreciated, thanks again. 